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WO2015146819A1 - Wire harness, connection method between covered conducting wire and terminal, and wire harness structure body - Google Patents

Wire harness, connection method between covered conducting wire and terminal, and wire harness structure body Download PDF

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Publication number
WO2015146819A1
WO2015146819A1 PCT/JP2015/058437 JP2015058437W WO2015146819A1 WO 2015146819 A1 WO2015146819 A1 WO 2015146819A1 JP 2015058437 W JP2015058437 W JP 2015058437W WO 2015146819 A1 WO2015146819 A1 WO 2015146819A1
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WO
WIPO (PCT)
Prior art keywords
wire
crimping
coated
compression
conductor
Prior art date
Application number
PCT/JP2015/058437
Other languages
French (fr)
Japanese (ja)
Inventor
泰 木原
幸大 川村
翔 外池
隆人 中嶋
小林　浩
大泰 多賀
Original Assignee
古河電気工業株式会社
古河As株式会社
トヨタ自動車株式会社
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by 古河電気工業株式会社, 古河As株式会社, トヨタ自動車株式会社 filed Critical 古河電気工業株式会社
Priority to JP2016510294A priority Critical patent/JP6117426B2/en
Priority to EP15769188.2A priority patent/EP3125369B1/en
Priority to KR1020167022102A priority patent/KR101833659B1/en
Priority to CN201580006905.2A priority patent/CN105940557B/en
Priority to US15/127,630 priority patent/US10305240B2/en
Publication of WO2015146819A1 publication Critical patent/WO2015146819A1/en

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H01R43/0488—Crimping apparatus or processes with crimp height adjusting means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R16/00—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for
    • B60R16/02—Electric or fluid circuits specially adapted for vehicles and not otherwise provided for; Arrangement of elements of electric or fluid circuits specially adapted for vehicles and not otherwise provided for electric constitutive elements
    • B60R16/0207—Wire harnesses
    • B60R16/0215—Protecting, fastening and routing means therefor
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/0045—Cable-harnesses
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/10—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation
    • H01R4/18—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping
    • H01R4/183—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section
    • H01R4/184—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion
    • H01R4/185—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation effected solely by twisting, wrapping, bending, crimping, or other permanent deformation by crimping for cylindrical elongated bodies, e.g. cables having circular cross-section comprising a U-shaped wire-receiving portion combined with a U-shaped insulation-receiving portion
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/58—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation characterised by the form or material of the contacting members
    • H01R4/62—Connections between conductors of different materials; Connections between or with aluminium or steel-core aluminium conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R4/00—Electrically-conductive connections between two or more conductive members in direct contact, i.e. touching one another; Means for effecting or maintaining such contact; Electrically-conductive connections having two or more spaced connecting locations for conductors and using contact members penetrating insulation
    • H01R4/70—Insulation of connections
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/048—Crimping apparatus or processes
    • H01R43/05—Crimping apparatus or processes with wire-insulation stripping
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
    • H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
    • H01R43/058—Crimping mandrels
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
    • H01R2201/00—Connectors or connections adapted for particular applications
    • H01R2201/26—Connectors or connections adapted for particular applications for vehicles

Definitions

  • the present invention relates to a wire harness used for an automobile or the like.
  • connection between an electric wire and a terminal in an automobile wire harness is generally a crimp bonding in which the electric wire is crimped with a terminal called an open barrel type.
  • a wire harness when moisture or the like adheres to the connection portion between the electric wire and the terminal, the oxidation of the metal surface used for the electric wire proceeds, and the resistance at the joint increases.
  • the metal used for an electric wire and a terminal differs, the corrosion between different metals will advance. The progress of the corrosion of the metal material in the connection portion causes cracks in the connection portion and contact failure, and thus cannot be affected by the product life.
  • wire harnesses in which the electric wires are made of an aluminum alloy and the terminals are made of a copper alloy are being put into practical use, and the problem of corrosion at the joints has become prominent.
  • the present invention has been made in view of such problems, and an object of the present invention is to provide a wire harness or the like that can ensure water-stopping.
  • a first invention is a wire harness in which a coated conductor and a terminal are connected, and the terminal includes a crimping portion to which the coated conductor is crimped, and a terminal body.
  • the crimping part has a covering crimping part for crimping the covering part and a lead crimping part for crimping the conductor exposed from the covering part, and other parts are sealed except for the part where the covering conductor is inserted.
  • the wire harness is characterized in that a compression rate of the conducting wire is 50% to 80% and a compression rate of the covering portion is 40% to 90% in the covered crimp portion.
  • the compression ratio of the covering portion is 50 to 80%.
  • the compressibility of the conducting wire in the coated crimping portion is greater than or equal to the compressibility of the conducting wire in the conducting wire crimping portion.
  • the longitudinal elastic modulus of the resin constituting the covering portion is in the range of 10 MPa to 500 MPa at 20 ° C.
  • the thickness of the covering portion is desirably in the range of 0.16 mm to 0.40 mm.
  • the conducting wire is pure aluminum.
  • the conductor is preferably a stranded wire.
  • the lead wire before crimping is preferably an uncompressed conductor.
  • the compressibility of each of the conductor portion of the terminal and the covering portion of the coated conductor is appropriate, it is possible to reliably ensure water-stopping.
  • the covering portion is a plastic deformation region, and the adhesion between the covering portion and the terminal can be improved.
  • the conductor portion is a plastic deformation region, the conductor portion can be securely crimped and held.
  • the compressibility of the lead wire in the coated crimping portion is greater than or equal to the compressibility of the lead wire in the lead crimping portion (that is, the compression amount of the lead wire in the lead crimping portion is the compression amount of the lead wire in the covering crimp portion).
  • the tensile strength of the coated conductor with respect to the terminal can be improved. This is because if the compressibility of the conducting wire in the coated crimping portion is small, the cross-sectional area of the conducting wire is smaller than that of the conductor crimping portion, and there is a risk of stress concentration and breakage when the coated electric wire is pulled.
  • Such an effect is particularly effective when the longitudinal elastic modulus of the resin constituting the covering portion is in the range of 10 MPa to 500 MPa at 20 ° C. Further, it is particularly effective when the thickness of the covering portion is in the range of 0.16 mm to 0.40 mm.
  • the lead wire since the hardness is low when the lead wire is made of pure aluminum, the lead wire is easily deformed during compression, and the lead wire can be reliably deformed.
  • the conducting wire when the conducting wire is a stranded wire, there is a gap between the strands, which makes it easier to deform the conducting wire.
  • the conducting wire when the conducting wire is an incompressible conductor, the conducting wire is easily deformed. Thus, if the deformation of the conducting wire is easy to proceed, the compressibility of the conducting wire can be easily increased.
  • a second invention is a method for connecting a coated conductor and a terminal, wherein the terminal includes a crimping portion to which the coated conductor is crimped, and a terminal body, and the crimping portion crimps the coating portion. And a lead wire crimping part for crimping the lead wire exposed from the sheath part, and other parts are sealed except for the part where the covered lead wire is inserted.
  • the compression rate of the conductor in the coated crimping part is set to 40% to 80%, and the compression rate of the coated part is set to 40% to 90%. It is the connection method of the covered conductor and the terminal characterized.
  • a third invention is a wire harness structure in which a plurality of wire harnesses are bundled, wherein the wire harness is connected to a covered conductor and a terminal, and the terminal is crimped to the covered conductor.
  • the other portions are sealed except for the portion to be applied, and the compression rate of the conductive wire in the coated crimping portion is 40% to 80%, and the compression rate of the coated portion is 40% to 90%.
  • This is a wire harness structure.
  • a plurality of wire harnesses can be bundled and used.
  • FIG. The perspective view which shows the terminal 1.
  • FIG. The perspective view which shows the terminal 1 and the covering conducting wire 23 before crimping
  • Sectional drawing which shows the state which has arrange
  • Sectional drawing which shows the shape of metal mold
  • Sectional drawing which shows the terminal 1 and the covering conducting wire 23 before crimping.
  • FIG. Schematic shows a test apparatus.
  • FIG. 1 is a perspective view of the terminal 1. As shown in FIG. 1, the terminal 1 includes a terminal body 3 and a crimping portion 5.
  • Terminal 1 is made of copper.
  • the terminal body 3 is formed by forming a plate material having a predetermined shape into a cylindrical body having a rectangular cross section.
  • the terminal body 3 has an elastic contact piece 15 formed at the front end portion 17 by folding a plate material into a rectangular cylinder.
  • the terminal body 3 is connected by inserting a male terminal or the like from the front end portion 17.
  • the crimping part 5 is formed by rounding so that the cross section becomes a circular cylindrical body, butting the side edge parts together and joining and joining them at the joining part 21.
  • a coated conductor which will be described later, is inserted from the rear end portion 19 of the crimp portion 5 formed in a cylindrical shape.
  • a sealing portion 22 is provided at the front end portion (terminal body 3 side) of the crimping portion 5. That is, the crimping part 5 is sealed except for the rear end part 19 into which the coated conductor is inserted.
  • the junction part 21 and the sealing part 22 are welded by laser welding etc., for example.
  • compression-bonding part 5 shows the example which is a cylindrical shape of a fixed diameter
  • this invention is not limited to this.
  • the diameter of the portion to which the covering portion is pressure-bonded may be made larger than the diameter of the portion to which the conductive wire is crimped. In this case, a step whose diameter changes is formed in the crimping portion 5.
  • FIG. 2A and FIG. 2B are diagrams showing a connection process between the terminal 1 and the covered conductor 23.
  • the covered conducting wire 23 is inserted into the tubular crimping part 5.
  • the crimping part 5 is rounded into a substantially cylindrical shape, and the edges are joined by the joining part 21.
  • a sealing portion 22 is provided at the front end portion (terminal body 3 side) of the crimping portion 5. That is, the crimping part 5 is sealed except for the rear end part 19 into which the covered conducting wire 23 is inserted.
  • the conductor 25 is covered with an insulating coating 27.
  • the conductive wire 25 is made of, for example, an aluminum-based material, and is particularly preferably a pure aluminum-based material having low hardness and excellent workability.
  • the covered conductor 23 is inserted into the crimping part 5, a part of the cover 27 at the tip of the covered conductor 23 is peeled off to expose the conductor 25.
  • coated part 27 it is desirable that they are polyvinyl chloride (PVC), polyethylene, etc.
  • the crimping part 5 is compressed by a mold. Thereby, the crimping
  • FIG. As described above, the coated conductor 23 and the terminal 1 are connected, and the wire harness 30 is manufactured.
  • FIG. 3 is a longitudinal sectional view showing a state in which the terminal 1 and the covered conductor 23 are disposed between the molds 31a and 31b.
  • 4 is a diagram showing the shapes of the molds 31a and 31b, and is a cross-sectional view taken along the line AA in FIG. 3 (the illustration of the terminal 1 and the like is omitted). Between the molds 31a and 31b, the crimping part 5 of the terminal 1 into which the covered conductor 23 is inserted is disposed.
  • the crimping part 5 includes a lead crimping part for crimping the conductor 25 exposed from the covering part 27 and a covering crimping part for crimping the covering part 27.
  • a lead crimping part for crimping the conductor 25 exposed from the covering part 27
  • a covering crimping part for crimping the covering part 27.
  • detailed description of the lead wire crimping portion is omitted.
  • the molds 31a and 31b to which the covering portion 27 is crimped have a substantially semicircular inner shape, and the mold 31b and the mold 31a are combined (arrow C in the figure).
  • a substantially circular compressed shape can be obtained. That is, the terminal 1 (crimp part 5) and the covering part 27 (covered conductive wire 23) sandwiched between the molds 31a and 31b can be compressed into a substantially circular cross-sectional shape.
  • FIG. 5A is a cross-sectional view showing a state where the coated conductor 23 is inserted into the crimping part 5 before compression
  • FIG. 5B shows a state where the coated conductor 23 is inserted into the crimped part 5 after compression. It is sectional drawing shown.
  • a compression cross-section having a substantially circular cross-sectional shape is obtained.
  • the conducting wire 25 is a strand of a plurality of strands. Each strand is a non-compressed conductor.
  • the cross-sectional area of the conducting wire 25 before compression is A0. That is, the sum of the cross-sectional areas of the respective strands before compression is A0. Moreover, let B0 be the cross-sectional area of the covering portion 27 before compression.
  • the cross-sectional area of the conducting wire 25 in the compressed state is A1. That is, the sum of the cross-sectional areas of the respective strands after compression is A1.
  • B1 be the cross-sectional area of the cover 27 after compression.
  • the cross-sectional area of the electric wire in the part not crimped is defined as the sectional area before crimping.
  • the compression rate of the conductor 25 in the coated crimping part is set to 50 to 80%.
  • the compression rate of the covering portion 27 is set at 40 to 90%.
  • the compression amount by the molds 31a and 31b is set so as to be in such a range. If the compressibility of the conductor 25 is too small, the conductor 25 may be broken. Moreover, when the compressibility of the conducting wire 25 is too large, the gap between the strands becomes large and there is a risk of water intrusion. Further, if the compressibility of the covering portion 27 is too small, the covering portion 27 may be broken at a portion where stress is concentrated. Moreover, when the compressibility of the coating
  • the compression ratio is calculated by (cross-sectional area after compression) / (cross-sectional area before compression). That is, a compression rate of 80% means that the cross-sectional area has been reduced by 20% due to compression. That is, in the present invention, the relationship of 80% ⁇ A1 / A0 ⁇ 50% and 90% ⁇ B1 / B0 ⁇ 40% is satisfied.
  • the conducting wire 25 is usually a stranded wire in which a plurality of strands are twisted together.
  • each strand is arranged in a plurality of layers from the center, the strand on the center side is surrounded by other strands, and the outer peripheral surface of the outermost strand is in contact with the covering portion 27.
  • all the strands may be compressed at a constant rate, but the compression rate of the outermost strand may be lower than the compression rate of the inner strand.
  • the inner strands are deformed into a substantially hexagonal shape, adjacent strands come into contact with each other in the cross section, the gap between the strands can be reduced, and the leakage transmitted between the strands Can be suppressed.
  • the covering portion 27 is close to the shape before compression, and the covering portion 27 can be uniformly compressed.
  • the shape of the mold, the physical properties of the covering portion 27, and the distortion of caulking during crimping The speed may be adjusted.
  • the processing may be performed so that the strain speed is in a dynamic load region of about 10 to 200 / sec.
  • FIG. 6 is a diagram showing the relationship between the compressibility of polyvinyl chloride and compression set.
  • the compression set is calculated based on JIS K6262. That is, assuming that the original thickness t0 of the sample, the thickness after compression (spacer thickness) is t1, and the thickness of the sample 30 minutes after releasing the compression is t2, the compression set is (t0-t2) / ( It is calculated as t0-t1).
  • the example shown in FIG. 6 shows the result of applying compression at 120 ° C. ⁇ 120 h.
  • the compression set is about 80%, which is smaller than 100%, and it can be seen that there is a restoration after the compression is released.
  • the compression rate is in the range of 50% to 80%
  • the compression set is a stable region where the compression set does not change much around the minimum value with respect to the change in the compression rate, and the repulsive force of the coating can be maintained stably. Since it can show aqueous property, it is preferable.
  • FIG. 7 is a diagram showing a change in compressive force depending on the holding time of the same resin in which a single coating material is formed into a plate shape.
  • D represents a case where the compression ratio is 80%
  • E in the figure represents a case where the compression ratio is 90%.
  • the holding time is a holding time at 120 ° C.
  • the compression force after holding can be maintained by setting the compression ratio of the resin in the range of 40% to 90%.
  • the compressibility of the conductor 25 is less than 50%, the amount of deformation of the metal becomes too large, and there is a risk of the conductor being broken.
  • the compressibility of the conducting wire exceeds 80%, the amount of deformation is small, and it is difficult to completely crush the entire conducting wire in the plastic deformation region. Therefore, it is desirable that the compressibility of the conducting wire is also in the range of 50% to 80%.
  • the compression rate of the conductive wire 25 in the above-described coated crimping portion is greater than or equal to the compression rate of the conductive wire 25 in the conductive wire crimping portion (that is, the compression amount of the conductive wire in the conductive wire crimping portion is covered and crimped. It is desirable that it is larger than the compression amount of the conducting wire in the portion. If the compression rate of the conductive wire 25 in the coated crimping portion is small, the cross-sectional area of the conductive wire 25 becomes smaller than that of the conductor crimped portion, and there is a risk of stress concentration and breakage when the coated conductive wire 23 is pulled.
  • the tensile strength of the covering conducting wire 23 with respect to the terminal 1 can be improved by making the compression rate of the conducting wire 25 in the covering crimping portion equal to or higher than the compressing rate of the conducting wire 25 in the conducting wire crimping portion.
  • the compressibility of the conductor 25 in the conductor crimping portion is preferably about 45 to 50%, for example.
  • the crimping part 5 and the covering part 27 can be securely adhered and the crimping part 5 can be sealed.
  • an appropriate compressive force remains in the covering portion 27 and the permanent strain is small. For this reason, sufficient adhesion between the crimping part 5 and the covering part 27 can be ensured.
  • other parts than the rear end part 19 of the crimping part 5 are sealed in a watertight manner by the joining part 21 and the sealing part 22, so that the intrusion of moisture into the crimping part 5 can be prevented.
  • the compressibility of the conductor 25 in the coated crimping portion is 50% to 80%
  • the compressibility of the covering portion 27 is 40% to 90% (more preferably 50% to 80%, 50% to 70%). If it is more desirable, the compression amount is appropriate for both the conductor 25 and the covering portion 27, and the mutual adhesion is also improved.
  • the compression amount of the covering portion 27 is likely to be larger than that of the conductive wire 25.
  • the conducting wire 25 is a stranded wire, the entire conducting wire is easily deformed by the gap between the strands. For this reason, it is easy to enlarge the compression amount of the conducting wire 25.
  • a compressed conductor obtained by compressing and twisting the conductor 25 in advance is used as the coated conductor.
  • the compressed conductor is already compressed before compression, it is difficult to deform further.
  • the conducting wire 25 it is desirable for the conducting wire 25 to be an incompressible conductor.
  • the longitudinal elastic modulus of the resin constituting the covering portion 27 is in the range of 10 MPa to 500 MPa at normal temperature (20 ° C.), sufficient adhesion after compression can be ensured.
  • the longitudinal elastic modulus of the resin constituting the covering portion 27 is desirably 10 MPa to 500 MPa, more desirably 28 MPa to 420 MPa at normal temperature (20 ° C.).
  • a resin for example, polyvinyl chloride (PVC) or polyethylene is desirable.
  • the longitudinal elastic modulus can be determined according to JIS-K7161, 7162 and the like.
  • the thickness of the covering portion 27 is desirably in the range of 0.16 mm to 0.40 mm. If the thickness of the covering portion 27 is too thin, there is a risk of tearing during compression if the compression ratio is in the above range. Moreover, when the thickness of the coating
  • the compressed covering portion 27 can be deformed in the plastic deformation region. Further, at this time, since the permanent distortion of the covering portion 27 is small and a compressive force can be ensured, adhesion with the crimping portion 5 can be ensured. For this reason, it is possible to ensure the water stoppage of the crimping part 5 and the covering part 27.
  • the compressibility of the conducting wire 25 is appropriate, there is no fear of the breaking of the conducting wire 25 after compression, and since the wire 25 is sufficiently deformed, the holding force of the conducting wire 25 is excellent.
  • FIG. 8 is a perspective view showing a wire harness 30a according to the second embodiment
  • FIG. 9 is a longitudinal sectional view of the crimping part 5 of the wire harness 30a.
  • components having the same functions as those of the wire harness 30 are denoted by the same reference numerals as those in FIG.
  • the wire harness 30 a has substantially the same configuration as that of the wire harness 30, but a ridge portion 29 is formed on the inner surface of the crimping portion 5.
  • the protruding portion 29 is formed at the position of the covering portion 27. Further, the ridge portion 29 is formed in an annular shape continuously in the circumferential direction of the inner surface of the crimping portion 5.
  • line parts 29 is not ask
  • the protruding line portion 29 is formed, for example, at the time of pressure bonding. For example, by forming a protrusion on the inner surface of the mold, a part of the crimping portion 5 is pushed by the protrusion. Therefore, the concave groove 7 is formed on the outer surface of the ridge 29. In this way, by compressing the covering portion 27 more strongly than the other portions by the ridge portion 29, the adhesion between the covering portion 27 and the crimping portion 5 can be ensured more reliably.
  • the cross section of the ridge portion 29 is set within the compression rate range described above.
  • the protruding strip portion 29 can ensure higher water stoppage.
  • FIG. 10 shows an outline of the experimental method.
  • the terminal 1 crimped to the covered conductor 23 was placed in a water tank 41 containing water, and pressurized air was sent from the end of the wire harness 30 toward the terminal 1 by the regulator 42 as necessary.
  • the test was conducted at three levels of 3 kPa, 30 kPa, and 50 kPa. At this time, with respect to 3 kPa, the terminal was submerged 30 cm from the water surface without using the regulator 42 to obtain a state of 3 kPa. The results are shown in Table 1.
  • No. 1 satisfies the condition that the compressibility of the coated portion in the coated crimp portion is 40 to 90% and the compressibility of the conductive wire in the coated crimp portion is 50 to 80%. No leakage at 3 kPa was confirmed for 5, 7 to 16 and 18. Further, in the case where the compression ratio of the covering portion in the covering and crimping portion is 50 to 80% and the compression ratio of the conductive wire in the covering and crimping portion is 50 to 80%, In Nos. 7 to 16, no leak was confirmed even at 30 kPa.
  • the compression rate of the coated part in the coated crimping part is 50 to 70%, and the compression rate of the conductive wire in the coated crimped part satisfies the conditions of 50 to 80%. In Nos. 7 to 13, no leak was confirmed even at 50 kPa.
  • a plurality of wire harnesses according to the present invention can be bundled and used.
  • a structure in which a plurality of wire harnesses are bundled in this way is referred to as a wire harness structure.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
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  • Insulated Conductors (AREA)
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Abstract

Upon compression with dies (31a, 31b), a conducting wire (25), a cover part (27), and a crimp part (5) become compressed, and thus, the cross-sections thereof decrease. Under such circumstances, A1 is the cross-section of the conducting wire (25) in the post-compression state. That is to say, A1 is the total sum of the cross-sections of all wire strands after the compression. In addition, B1 is the cross-section of the cover part (27) after the compression. In the present invention, the compression ratio that is set for the conducting wire (25) is 50 to 80%. In addition, the compression ratio that is set for the cover part (27) is 40 to 90%. The amount of compression by the dies (31a, 31b) is set so as to yield these ranges. In the present invention, the compression ratio is calculated by: (cross-section after compression)/(cross-section prior to compression). That is to say, 80% compression ratio means that the cross-section has decreased by 20% due to the compression. That is to say: 80% ≥ A1/A0 ≥ 50%, and 90% ≥ B1/B0 ≥ 40%.

Description

ワイヤハーネス、被覆導線と端子との接続方法、およびワイヤハーネス構造体Wire harness, method for connecting coated conductor and terminal, and wire harness structure
　本発明は自動車等に用いられるワイヤハーネス等に関するものである。 The present invention relates to a wire harness used for an automobile or the like.
　従来、自動車用ワイヤハーネスにおける電線と端子との接続は、オープンバレル型と呼ばれる端子で電線をかしめて圧着する圧着接合が一般的である。しかし、このようなワイヤハーネスでは、電線と端子の接続部分に水分等が付着してしまうと、電線に用いられる金属表面の酸化が進み、接合部における抵抗が増加してしまう。また電線と端子に用いられる金属が異なる場合、異種金属間腐食が進んでしまう。当該接続部分における金属材料の腐食の進行は、接続部分の割れや接触不良の原因となり、製品寿命への影響を免れない。特に近年では、電線をアルミニウム合金とし、端子を銅合金とするワイヤハーネスが実用化されつつあり、接合部の腐食の課題が顕著になってきている。 Conventionally, the connection between an electric wire and a terminal in an automobile wire harness is generally a crimp bonding in which the electric wire is crimped with a terminal called an open barrel type. However, in such a wire harness, when moisture or the like adheres to the connection portion between the electric wire and the terminal, the oxidation of the metal surface used for the electric wire proceeds, and the resistance at the joint increases. Moreover, when the metal used for an electric wire and a terminal differs, the corrosion between different metals will advance. The progress of the corrosion of the metal material in the connection portion causes cracks in the connection portion and contact failure, and thus cannot be affected by the product life. Particularly in recent years, wire harnesses in which the electric wires are made of an aluminum alloy and the terminals are made of a copper alloy are being put into practical use, and the problem of corrosion at the joints has become prominent.
　ここで、例えばアルミニウムと銅のような異種金属の接触部分に水分が付着すると、腐食電位の違いから、いわゆる電食が発生する恐れがある。特に、アルミニウムと銅との電位差は大きいから、電気的に卑であるアルミニウム側の腐食が進行する。このため、導線と圧着端子との接続状態が不安定となり、接触抵抗の増加や線径の減少による電気抵抗の増大、さらには断線が生じて電装部品の誤動作、機能停止に至る恐れがある。 Here, for example, if moisture adheres to the contact portion of different metals such as aluminum and copper, so-called galvanic corrosion may occur due to the difference in corrosion potential. In particular, since the potential difference between aluminum and copper is large, corrosion on the aluminum side, which is electrically base, proceeds. For this reason, the connection state between the conducting wire and the crimp terminal becomes unstable, and there is a possibility that the electrical resistance increases due to an increase in contact resistance or a decrease in the wire diameter, and further, disconnection occurs, leading to malfunction of the electrical component or a malfunction.
　このような異種金属が接触するワイヤハーネスにおいて、電線と圧着端子との接続部を覆うように樹脂材を充填したものがある（特許文献１）。樹脂材を充填することによって、電線と圧着端子との接触部分に水分が付着するのを防止する。 There is a wire harness that is in contact with such a dissimilar metal and that is filled with a resin material so as to cover the connection portion between the electric wire and the crimp terminal (Patent Document 1). By filling the resin material, moisture is prevented from adhering to the contact portion between the electric wire and the crimp terminal.
特開２００４－１１１０５８号公報JP 2004-111058 A
　しかし、特許文献１の方法では、樹脂材を別途充填しなければならないので、製造工程が複雑になり、その分、製造工程における管理も複雑化するという問題が生じる。また、工程が複雑になった分、ワイヤハーネス全体のコストも上がってしまう。 However, in the method of Patent Document 1, since the resin material must be separately filled, the manufacturing process becomes complicated, and accordingly, the management in the manufacturing process becomes complicated. In addition, the cost of the entire wire harness increases due to the complexity of the process.
　本発明は、このような問題に鑑みてなされたもので、確実に止水性を確保可能なワイヤハーネス等を提供することを目的とする。 The present invention has been made in view of such problems, and an object of the present invention is to provide a wire harness or the like that can ensure water-stopping.
　前述した目的を達するために第１の発明は、被覆導線と端子とが接続されるワイヤハーネスであって、前記端子は、前記被覆導線が圧着される圧着部と、端子本体と、を具備し、前記圧着部は、被覆部を圧着する被覆圧着部と、前記被覆部から露出する導線を圧着する導線圧着部とを有し、前記被覆導線が挿入される部位を除き、他の部位が封止されており、前記被覆圧着部における、前記導線の圧縮率が５０％～８０％であり、前記被覆部の圧縮率が４０％～９０％であることを特徴とするワイヤハーネスである。 In order to achieve the above-mentioned object, a first invention is a wire harness in which a coated conductor and a terminal are connected, and the terminal includes a crimping portion to which the coated conductor is crimped, and a terminal body. The crimping part has a covering crimping part for crimping the covering part and a lead crimping part for crimping the conductor exposed from the covering part, and other parts are sealed except for the part where the covering conductor is inserted. The wire harness is characterized in that a compression rate of the conducting wire is 50% to 80% and a compression rate of the covering portion is 40% to 90% in the covered crimp portion.
　前記被覆部の圧縮率が５０～８０％であることがさらに望ましい。 More preferably, the compression ratio of the covering portion is 50 to 80%.
　前記被覆圧着部における前記導線の圧縮率は、前記導線圧着部における前記導線の圧縮率に比べて大きいか等しいことが望ましい。 It is desirable that the compressibility of the conducting wire in the coated crimping portion is greater than or equal to the compressibility of the conducting wire in the conducting wire crimping portion.
　前記被覆部を構成する樹脂の縦弾性率が、２０℃において、１０ＭＰａ～５００ＭＰａの範囲であることが望ましい。 It is desirable that the longitudinal elastic modulus of the resin constituting the covering portion is in the range of 10 MPa to 500 MPa at 20 ° C.
　前記被覆部の厚さが、０．１６ｍｍ～０．４０ｍｍの範囲であることが望ましい。 The thickness of the covering portion is desirably in the range of 0.16 mm to 0.40 mm.
　前記導線は、純アルミニウムであることが望ましい。 It is desirable that the conducting wire is pure aluminum.
　前記導線は、撚り線であることが望ましい。 The conductor is preferably a stranded wire.
　圧着前の前記導線は、非圧縮導体であることが望ましい。 The lead wire before crimping is preferably an uncompressed conductor.
　第１の発明によれば、端子の導体部と被覆導線の被覆部のそれぞれの圧縮率が適正であるため、確実に止水性を確保することができる。特に、被覆部が塑性変形領域であり、被覆部と端子の密着性を高めることができる。また、導体部が塑性変形領域であるため、導体部を確実に圧着して保持することができる。 According to the first invention, since the compressibility of each of the conductor portion of the terminal and the covering portion of the coated conductor is appropriate, it is possible to reliably ensure water-stopping. In particular, the covering portion is a plastic deformation region, and the adhesion between the covering portion and the terminal can be improved. Further, since the conductor portion is a plastic deformation region, the conductor portion can be securely crimped and held.
　このように、被覆圧着部における導線の圧縮率が、導線圧着部における導線の圧縮率に比べて大きいか等しい（すなわち、導線圧着部での導線の圧縮量が、被覆圧着部における導線の圧縮量よりも大きい）と、端子に対する被覆導線の引張強度を向上することができる。これは、被覆圧着部における導線の圧縮率が小さいと、導体圧着部に比べて導線の断面積が小さくなり、被覆電線を引っ張ったときに応力集中して破断する恐れがあるためである。
Thus, the compressibility of the lead wire in the coated crimping portion is greater than or equal to the compressibility of the lead wire in the lead crimping portion (that is, the compression amount of the lead wire in the lead crimping portion is the compression amount of the lead wire in the covering crimp portion). And the tensile strength of the coated conductor with respect to the terminal can be improved. This is because if the compressibility of the conducting wire in the coated crimping portion is small, the cross-sectional area of the conducting wire is smaller than that of the conductor crimping portion, and there is a risk of stress concentration and breakage when the coated electric wire is pulled.
　このような効果は、特に、被覆部を構成する樹脂の縦弾性率が、２０℃において、１０ＭＰａ～５００ＭＰａの範囲である場合に特に有効である。また、被覆部の厚さが、０．１６ｍｍ～０．４０ｍｍの範囲である場合に特に有効である。 Such an effect is particularly effective when the longitudinal elastic modulus of the resin constituting the covering portion is in the range of 10 MPa to 500 MPa at 20 ° C. Further, it is particularly effective when the thickness of the covering portion is in the range of 0.16 mm to 0.40 mm.
　また、導線が純アルミニウム製であると、硬度が低いため、圧縮時に導線の変形が進行しやすく、確実に導線を変形させることができる。特に、導線が撚り線の場合には、素線間に隙間があるため、導線をより変形させやすい。さらに、導線が非圧縮導体である場合には、導線を変形させやすい。このように、導線の変形が進みやすいと、導線の圧縮率を容易に高めることができる。 Moreover, since the hardness is low when the lead wire is made of pure aluminum, the lead wire is easily deformed during compression, and the lead wire can be reliably deformed. In particular, when the conducting wire is a stranded wire, there is a gap between the strands, which makes it easier to deform the conducting wire. Furthermore, when the conducting wire is an incompressible conductor, the conducting wire is easily deformed. Thus, if the deformation of the conducting wire is easy to proceed, the compressibility of the conducting wire can be easily increased.
　第２の発明は、被覆導線と端子との接続方法であって、前記端子は、前記被覆導線が圧着される圧着部と、端子本体と、を具備し、前記圧着部は、被覆部を圧着する被覆圧着部と、前記被覆部から露出する導線を圧着する導線圧着部とを有し、前記被覆導線が挿入される部位を除き、他の部位が封止されており、前記圧着部に前記被覆導線を挿入し、前記圧着部を圧着する際に、前記被覆圧着部における、前記導線の圧縮率を４０％～８０％とし、前記被覆部の圧縮率を４０％～９０％とすることを特徴とする被覆導線と端子との接続方法である。 A second invention is a method for connecting a coated conductor and a terminal, wherein the terminal includes a crimping portion to which the coated conductor is crimped, and a terminal body, and the crimping portion crimps the coating portion. And a lead wire crimping part for crimping the lead wire exposed from the sheath part, and other parts are sealed except for the part where the covered lead wire is inserted. When inserting the coated conductor and crimping the crimping part, the compression rate of the conductor in the coated crimping part is set to 40% to 80%, and the compression rate of the coated part is set to 40% to 90%. It is the connection method of the covered conductor and the terminal characterized.
　第２の発明によれば、止水性に優れたワイヤハーネスを製造することができる。 According to the second invention, it is possible to manufacture a wire harness having excellent water-stopping properties.
　第３の発明は、複数本のワイヤハーネスが束ねられたワイヤハーネス構造体であって、前記ワイヤハーネスは、被覆導線と端子とが接続されており、前記端子は、前記被覆導線が圧着される圧着部と、端子本体と、を具備し、前記圧着部は、被覆部を圧着する被覆圧着部と、前記被覆部から露出する導線を圧着する導線圧着部とを有し、前記被覆導線が挿入される部位を除き、他の部位が封止されており、前記被覆圧着部における、前記導線の圧縮率が４０％～８０％であり、前記被覆部の圧縮率が４０％～９０％であることを特徴とするワイヤハーネス構造体である。 A third invention is a wire harness structure in which a plurality of wire harnesses are bundled, wherein the wire harness is connected to a covered conductor and a terminal, and the terminal is crimped to the covered conductor. A crimping portion and a terminal body, wherein the crimping portion has a covering crimping portion for crimping the covering portion, and a conductor crimping portion for crimping a conductor exposed from the covering portion, and the covering conductor is inserted The other portions are sealed except for the portion to be applied, and the compression rate of the conductive wire in the coated crimping portion is 40% to 80%, and the compression rate of the coated portion is 40% to 90%. This is a wire harness structure.
　本発明では、複数本のワイヤハーネスを束ねて用いることもできる。 In the present invention, a plurality of wire harnesses can be bundled and used.
　本発明によれば、確実に止水性を確保可能なワイヤハーネス等を提供することができる。 According to the present invention, it is possible to provide a wire harness or the like that can ensure water-stopping.
端子１を示す斜視図。The perspective view which shows the terminal 1. FIG. 圧着前の端子１と被覆導線２３を示す斜視図。The perspective view which shows the terminal 1 and the covering conducting wire 23 before crimping | compression-bonding. ワイヤハーネス３０を示す図。The figure which shows the wire harness 30. 金型３１ａ、３１ｂの間に、端子１と被覆導線２３を配置した状態を示す断面図。Sectional drawing which shows the state which has arrange | positioned the terminal 1 and the covering conducting wire 23 between metal mold | die 31a, 31b. 金型３１ａ、３１ｂの形状を示す断面図。Sectional drawing which shows the shape of metal mold | die 31a, 31b. 圧着前の端子１と被覆導線２３を示す断面図。Sectional drawing which shows the terminal 1 and the covering conducting wire 23 before crimping. 圧着後の端子１と被覆導線２３を示す断面図。Sectional drawing which shows the terminal 1 and the covering conducting wire 23 after crimping | compression-bonding. 樹脂の圧縮率と圧縮永久ひずみの関係を示す図。The figure which shows the relationship between the compression rate of resin, and compression set. 樹脂の高温保持時間と圧縮力の変化を示す図。The figure which shows the high temperature holding time of resin, and the change of compressive force. ワイヤハーネス３０ａを示す図。The figure which shows the wire harness 30a. 圧着部５の断面図。Sectional drawing of the crimping | compression-bonding part 5. FIG. 試験装置を示す概略図。Schematic which shows a test apparatus.
（第１の実施の形態）
　以下、図面に基づいて、本発明の第１の実施の形態について詳細に説明する。図１は、端子１の斜視図である。図１に示すように、端子１は、端子本体３と圧着部５とからなる。 (First embodiment)
Hereinafter, a first embodiment of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view of the terminal 1. As shown in FIG. 1, the terminal 1 includes a terminal body 3 and a crimping portion 5.
　端子１は、銅製である。端子本体３は、所定の形状の板材を、断面が矩形の筒体に形成したものである。端子本体３は、前端部１７に、板材を矩形の筒体内に折り込んで形成される弾性接触片１５を有する。端子本体３は、前端部１７から雄端子などが挿入されて接続される。 Terminal 1 is made of copper. The terminal body 3 is formed by forming a plate material having a predetermined shape into a cylindrical body having a rectangular cross section. The terminal body 3 has an elastic contact piece 15 formed at the front end portion 17 by folding a plate material into a rectangular cylinder. The terminal body 3 is connected by inserting a male terminal or the like from the front end portion 17.
　圧着部５は、断面が円形の筒体となるように丸められ、側縁部同士を突き合わせて接合部２１で接合して一体化することにより形成される。筒状に形成された圧着部５の後端部１９から、後述する被覆導線が挿入される。また、圧着部５の前端部（端子本体３側）には封止部２２が設けられる。すなわち、圧着部５は、被覆導線が挿入される後端部１９以外は、封止される。なお、接合部２１および封止部２２は、例えばレーザ溶接等によって溶接される。 The crimping part 5 is formed by rounding so that the cross section becomes a circular cylindrical body, butting the side edge parts together and joining and joining them at the joining part 21. A coated conductor, which will be described later, is inserted from the rear end portion 19 of the crimp portion 5 formed in a cylindrical shape. A sealing portion 22 is provided at the front end portion (terminal body 3 side) of the crimping portion 5. That is, the crimping part 5 is sealed except for the rear end part 19 into which the coated conductor is inserted. In addition, the junction part 21 and the sealing part 22 are welded by laser welding etc., for example.
　なお、圧着部５は、一定の径の筒状である例を示すが、本発明はこれに限られない。例えば、圧着部５において、被覆導線の導線を圧着する部位と、被覆部を圧着する部位とで、径を変えてもよい。より詳細には、導線を圧着する部位の径よりも、被覆部を圧着する部位の径を大きくしてもよい。この場合には、圧着部５に、径の変化する段差が形成される。 In addition, although the crimping | compression-bonding part 5 shows the example which is a cylindrical shape of a fixed diameter, this invention is not limited to this. For example, in the crimping part 5, you may change a diameter by the site | part which crimps | bonds the conducting wire of a covered conducting wire, and the site | part which crimps | bonds a coating | coated part. More specifically, the diameter of the portion to which the covering portion is pressure-bonded may be made larger than the diameter of the portion to which the conductive wire is crimped. In this case, a step whose diameter changes is formed in the crimping portion 5.
　次に、ワイヤハーネスを形成する工程について説明する。図２（ａ）、図２（ｂ）は、端子１と被覆導線２３との接続工程を示す図である。まず、図２（ａ）に示すように、筒状の圧着部５に被覆導線２３を挿入する。前述したように、圧着部５は、略筒状に丸められて、縁部同士が接合部２１で接合される。また、圧着部５の前端部（端子本体３側）には封止部２２が設けられる。すなわち、圧着部５は、被覆導線２３が挿入される後端部１９以外は、封止される。 Next, the process for forming the wire harness will be described. FIG. 2A and FIG. 2B are diagrams showing a connection process between the terminal 1 and the covered conductor 23. First, as shown in FIG. 2A, the covered conducting wire 23 is inserted into the tubular crimping part 5. As described above, the crimping part 5 is rounded into a substantially cylindrical shape, and the edges are joined by the joining part 21. A sealing portion 22 is provided at the front end portion (terminal body 3 side) of the crimping portion 5. That is, the crimping part 5 is sealed except for the rear end part 19 into which the covered conducting wire 23 is inserted.
　被覆導線２３は、導線２５が絶縁性の被覆部２７によって被覆される。導線２５は、例えばアルミニウム系材料製であり、特に、硬度が低く、加工性に優れる純アルミニウム系であることが望ましい。被覆導線２３を圧着部５に挿入する際には、被覆導線２３の先端の一部の被覆部２７が剥離され、導線２５を露出させておく。なお、被覆部２７としては、ポリ塩化ビニル（ＰＶＣ）、ポリエチレン等であることが望ましい。 In the coated conductor 23, the conductor 25 is covered with an insulating coating 27. The conductive wire 25 is made of, for example, an aluminum-based material, and is particularly preferably a pure aluminum-based material having low hardness and excellent workability. When the covered conductor 23 is inserted into the crimping part 5, a part of the cover 27 at the tip of the covered conductor 23 is peeled off to expose the conductor 25. In addition, as the coating | coated part 27, it is desirable that they are polyvinyl chloride (PVC), polyethylene, etc.
　次に、図２（ｂ）に示すように金型によって、圧着部５を圧縮する。これにより、圧着部５が導線２５および被覆部２７と圧着される。以上により、被覆導線２３と端子１とが接続されて、ワイヤハーネス３０が製造される。 Next, as shown in FIG. 2 (b), the crimping part 5 is compressed by a mold. Thereby, the crimping | compression-bonding part 5 is crimped | bonded with the conducting wire 25 and the coating | coated part 27. FIG. As described above, the coated conductor 23 and the terminal 1 are connected, and the wire harness 30 is manufactured.
　図３は、金型３１ａ、３１ｂの間に、端子１と被覆導線２３を配置した状態を示す長手方向断面図である。また、図４は、金型３１ａ、３１ｂの形状を示す図であり、図３のＡ－Ａ線断面図（端子１等の図示は省略する）である。金型３１ａ、３１ｂの間には、被覆導線２３が挿入された端子１の圧着部５が配置される。 FIG. 3 is a longitudinal sectional view showing a state in which the terminal 1 and the covered conductor 23 are disposed between the molds 31a and 31b. 4 is a diagram showing the shapes of the molds 31a and 31b, and is a cross-sectional view taken along the line AA in FIG. 3 (the illustration of the terminal 1 and the like is omitted). Between the molds 31a and 31b, the crimping part 5 of the terminal 1 into which the covered conductor 23 is inserted is disposed.
　圧着部５は、被覆部２７から露出した導線２５を圧着する導線圧着部と、被覆部２７を圧着する被覆圧着部とからなる。本発明においては、導線圧着部については、詳細な説明を省略する。 The crimping part 5 includes a lead crimping part for crimping the conductor 25 exposed from the covering part 27 and a covering crimping part for crimping the covering part 27. In the present invention, detailed description of the lead wire crimping portion is omitted.
　図４に示すように、被覆部２７を圧着する部位の金型３１ａ、３１ｂは、略半円の内面形状を有し、金型３１ｂと金型３１ａとを組み合わせることで（図中矢印Ｃ）、略円形の圧縮形状を得ることができる。すなわち、金型３１ａ、３１ｂで挟み込んだ端子１（圧着部５）および被覆部２７（被覆導線２３）を略円断面形状に圧縮することができる。 As shown in FIG. 4, the molds 31a and 31b to which the covering portion 27 is crimped have a substantially semicircular inner shape, and the mold 31b and the mold 31a are combined (arrow C in the figure). A substantially circular compressed shape can be obtained. That is, the terminal 1 (crimp part 5) and the covering part 27 (covered conductive wire 23) sandwiched between the molds 31a and 31b can be compressed into a substantially circular cross-sectional shape.
　図５（ａ）は、圧縮前の圧着部５に被覆導線２３が挿入された状態を示す断面図、図５（ｂ）は、圧縮後の圧着部５に被覆導線２３が挿入された状態を示す断面図である。圧縮前の断面形状に対して、金型３１ａ、３１ｂによって圧縮することで、略円断面形状の圧縮断面となる。なお、図示した例では、導線２５が複数の素線のより線である場合を示す。また、各素線は非圧縮導体である場合を示す。 FIG. 5A is a cross-sectional view showing a state where the coated conductor 23 is inserted into the crimping part 5 before compression, and FIG. 5B shows a state where the coated conductor 23 is inserted into the crimped part 5 after compression. It is sectional drawing shown. By compressing the cross-sectional shape before compression with the molds 31a and 31b, a compression cross-section having a substantially circular cross-sectional shape is obtained. In the illustrated example, the case where the conducting wire 25 is a strand of a plurality of strands is shown. Each strand is a non-compressed conductor.
　ここで、圧縮前の状態の導線２５の断面積をＡ０とする。すなわち、圧縮前の各素線の断面積の総和をＡ０とする。また、圧縮前の被覆部２７の断面積をＢ０とする。 Here, the cross-sectional area of the conducting wire 25 before compression is A0. That is, the sum of the cross-sectional areas of the respective strands before compression is A0. Moreover, let B0 be the cross-sectional area of the covering portion 27 before compression.
　これに対し、金型３１ａ、３１ｂによって圧縮すると、導線２５、被覆部２７、圧着部５は圧縮されるため、断面積が減少する。ここで、圧縮後の状態の導線２５の断面積をＡ１とする。すなわち、圧縮後の各素線の断面積の総和をＡ１とする。また、圧縮後の被覆部２７の断面積をＢ１とする。尚、被覆圧着部における圧縮前の導線２５や被覆部２７の断面積はわからないため、圧着されない部分の電線における断面積を圧着前の断面積とする。 On the other hand, when the dies 31a and 31b are compressed, the conductor 25, the covering portion 27, and the crimping portion 5 are compressed, so that the cross-sectional area is reduced. Here, the cross-sectional area of the conducting wire 25 in the compressed state is A1. That is, the sum of the cross-sectional areas of the respective strands after compression is A1. Moreover, let B1 be the cross-sectional area of the cover 27 after compression. In addition, since the cross-sectional area of the conducting wire 25 and the covering part 27 before compression in the coated crimping part is not known, the cross-sectional area of the electric wire in the part not crimped is defined as the sectional area before crimping.
　本発明では、被覆圧着部における導線２５の圧縮率は、５０～８０％で設定される。また、被覆部２７の圧縮率は４０～９０％で設定される。このような範囲となるように、金型３１ａ、３１ｂによる圧縮量を設定する。導線２５の圧縮率が小さすぎると、導線２５の断線の恐れがある。また、導線２５の圧縮率が大きすぎると、素線間の隙間が大きくなり、水の浸入の恐れがある。また、被覆部２７の圧縮率が小さすぎると、応力が集中する部分において被覆部２７が破断する恐れがある。また、被覆部２７の圧縮率が大きすぎると、十分な密着を得ることができず、水の浸入の恐れがある。 In the present invention, the compression rate of the conductor 25 in the coated crimping part is set to 50 to 80%. The compression rate of the covering portion 27 is set at 40 to 90%. The compression amount by the molds 31a and 31b is set so as to be in such a range. If the compressibility of the conductor 25 is too small, the conductor 25 may be broken. Moreover, when the compressibility of the conducting wire 25 is too large, the gap between the strands becomes large and there is a risk of water intrusion. Further, if the compressibility of the covering portion 27 is too small, the covering portion 27 may be broken at a portion where stress is concentrated. Moreover, when the compressibility of the coating | coated part 27 is too large, sufficient contact | adherence cannot be obtained and there exists a possibility of water permeation.
　ここで、本発明において圧縮率とは、（圧縮後の断面積）／（圧縮前の断面積）で算出される。すなわち、圧縮率８０％とは、圧縮によって、断面積が２０％減少したことを意味する。すなわち、本発明では、８０％≧Ａ１／Ａ０≧５０％、９０％≧Ｂ１／Ｂ０≧４０％の関係を満たす。 Here, in the present invention, the compression ratio is calculated by (cross-sectional area after compression) / (cross-sectional area before compression). That is, a compression rate of 80% means that the cross-sectional area has been reduced by 20% due to compression. That is, in the present invention, the relationship of 80% ≧ A1 / A0 ≧ 50% and 90% ≧ B1 / B0 ≧ 40% is satisfied.
　なお、導線２５は、通常、複数の素線が撚り合わせられた撚り線が用いられる。この場合、各素線は、中心から複数層に配置され、中心側の素線は外周を他の素線で囲まれ、最外周の素線の外周面は被覆部２７と接触する。この際、全ての素線が一定の割合で圧縮されてもよいが、最外周の素線の圧縮率を、内部側の素線の圧縮率よりも低くしてもよい。このようにすることで、例えば、内部側の素線はほぼ正六角形に変形し、隣り合う素線同士が断面において線で接触し、素線間の隙間を小さくでき、素線間を伝わるリークを抑制できる。また、最外周の素線の外周面には、断面において曲線部が残存することで、被覆部２７が圧縮前の形状に近く、被覆部２７を均一に圧縮させることができる。このように最外周の素線の圧縮率を、内部側の他の素線の圧縮率よりも低くするためには、金型の形状や被覆部２７の物性、および圧着時におけるかしめ加工の歪速度を調整すればよく、例えば、歪速度を１０～２００／ｓｅｃ程度の動的荷重の領域になるようにして加工すればよい。 In addition, the conducting wire 25 is usually a stranded wire in which a plurality of strands are twisted together. In this case, each strand is arranged in a plurality of layers from the center, the strand on the center side is surrounded by other strands, and the outer peripheral surface of the outermost strand is in contact with the covering portion 27. At this time, all the strands may be compressed at a constant rate, but the compression rate of the outermost strand may be lower than the compression rate of the inner strand. By doing so, for example, the inner strands are deformed into a substantially hexagonal shape, adjacent strands come into contact with each other in the cross section, the gap between the strands can be reduced, and the leakage transmitted between the strands Can be suppressed. In addition, since the curved portion remains in the cross section on the outer peripheral surface of the outermost strand, the covering portion 27 is close to the shape before compression, and the covering portion 27 can be uniformly compressed. Thus, in order to make the compression rate of the outermost strand lower than the compression rate of the other strands on the inner side, the shape of the mold, the physical properties of the covering portion 27, and the distortion of caulking during crimping The speed may be adjusted. For example, the processing may be performed so that the strain speed is in a dynamic load region of about 10 to 200 / sec.
　図６は、ポリ塩化ビニルの圧縮率と圧縮永久ひずみの関係を示す図である。圧縮永久ひずみは、ＪＩＳ　Ｋ６２６２に基づいて算出される。すなわち、試料の元の厚みｔ０、圧縮後の厚み（スペーサの厚み）をｔ１、圧縮を解放して３０分後の試料の厚みをｔ２とすると、圧縮永久ひずみは、（ｔ０－ｔ２）／（ｔ０－ｔ１）で算出される。なお、図６に示す例は、圧縮を１２０℃×１２０ｈで付与した結果を示す。 FIG. 6 is a diagram showing the relationship between the compressibility of polyvinyl chloride and compression set. The compression set is calculated based on JIS K6262. That is, assuming that the original thickness t0 of the sample, the thickness after compression (spacer thickness) is t1, and the thickness of the sample 30 minutes after releasing the compression is t2, the compression set is (t0-t2) / ( It is calculated as t0-t1). In addition, the example shown in FIG. 6 shows the result of applying compression at 120 ° C. × 120 h.
　図６に示すように、圧縮率が４０％～９０％の範囲では、圧縮永久ひずみが約８０％と１００％より小さく、圧縮開放後の復元があることが分かる。特に圧縮率が５０％～８０％の範囲では、圧縮永久ひずみが圧縮率の変化に対し最小値付近で余り変化しない安定領域であり、安定して被覆の反発力を維持することができ高い止水性を示すことができるため好ましい。 As shown in FIG. 6, when the compression ratio is in the range of 40% to 90%, the compression set is about 80%, which is smaller than 100%, and it can be seen that there is a restoration after the compression is released. In particular, when the compression rate is in the range of 50% to 80%, the compression set is a stable region where the compression set does not change much around the minimum value with respect to the change in the compression rate, and the repulsive force of the coating can be maintained stably. Since it can show aqueous property, it is preferable.
　図７は、被覆材単体を板状にした同様の樹脂の保持時間による圧縮力の変化を示す図である。図中Ｄは、圧縮率が８０％の場合、図中Ｅは、圧縮率が９０％の場合を示す図である。保持時間は１２０℃における保持時間である。 FIG. 7 is a diagram showing a change in compressive force depending on the holding time of the same resin in which a single coating material is formed into a plate shape. In the figure, D represents a case where the compression ratio is 80%, and E in the figure represents a case where the compression ratio is 90%. The holding time is a holding time at 120 ° C.
　図に示すように、圧縮率が８０％の場合、１２０℃で１２０時間後においても、３００ｋＰａ以上の圧縮力を維持する。一方、圧縮率が９０％では、保持時間とともに応力が緩和されて、１２０時間後には、５０ｋＰａ程度まで減少する。圧縮力が５０ｋＰａ以下となると、５０ｋＰａ程度のリークテストをした際に、圧力に対して圧縮力が負けて、リークする危険性が増す。つまり被覆材単体の状態で十分な圧縮力が得られない場合は、電線被覆を圧縮した時に十分な面圧を保てないと言える。一般に、電線と端子を圧着する場合は、上下方向（一軸方向）から加締めるため、応力分布ができ、電線の側面領域など圧縮応力が小さい領域からリークしやすい傾向となるため、被覆材単体での試験の場合に比べて圧縮率の値を小さくする必要がある。なお、圧着後のワイヤハーネスのエアリーク試験結果については後述する。 As shown in the figure, when the compression ratio is 80%, a compressive force of 300 kPa or more is maintained even after 120 hours at 120 ° C. On the other hand, when the compressibility is 90%, the stress is relaxed with the holding time, and after 120 hours, the stress is reduced to about 50 kPa. When the compressive force is 50 kPa or less, when a leak test of about 50 kPa is performed, the compressive force is lost with respect to the pressure, and the risk of leakage increases. That is, when a sufficient compressive force cannot be obtained in the state of the coating material alone, it can be said that a sufficient surface pressure cannot be maintained when the wire coating is compressed. In general, when crimping an electric wire and a terminal, since it is caulked from the vertical direction (uniaxial direction), stress distribution can occur, and it tends to leak from areas where the compressive stress is small, such as the side area of the electric wire. It is necessary to reduce the compression ratio as compared with the case of the test. In addition, the air leak test result of the wire harness after crimping will be described later.
　このように、本発明では、樹脂の圧縮率を４０％～９０％の範囲とすることで、保持後の圧縮力も維持することができる。 Thus, in the present invention, the compression force after holding can be maintained by setting the compression ratio of the resin in the range of 40% to 90%.
　なお、同様に、導線２５の圧縮率が５０％を下回ると、金属の変形量が大きくなりすぎるため、導線の破断の恐れがある。また、導線の圧縮率が８０％を超えると、変形量が小さく、導線全体を完全に塑性変形領域でつぶすことが困難である。したがって、導線の圧縮率も５０％～８０％の範囲であることが望ましい。 Similarly, if the compressibility of the conductor 25 is less than 50%, the amount of deformation of the metal becomes too large, and there is a risk of the conductor being broken. Moreover, when the compressibility of the conducting wire exceeds 80%, the amount of deformation is small, and it is difficult to completely crush the entire conducting wire in the plastic deformation region. Therefore, it is desirable that the compressibility of the conducting wire is also in the range of 50% to 80%.
　なお、本発明では、前述した被覆圧着部における導線２５の圧縮率が、導線圧着部における導線２５の圧縮率に比べて大きいか等しい（すなわち、導線圧着部での導線の圧縮量が、被覆圧着部における導線の圧縮量よりも大きい）ことが望ましい。被覆圧着部における導線２５の圧縮率が小さいと、導体圧着部に比べて導線２５の断面積が小さくなり、被覆導線２３を引っ張ったときに応力集中して破断する恐れがある。このため、被覆圧着部における導線２５の圧縮率を、導線圧着部における導線２５の圧縮率以上とすることで、端子１に対する被覆導線２３の引張強度を向上することができる。なお、導体圧着部における導線２５圧縮率は、例えば４５～５０％程度とすることが望ましい。 In the present invention, the compression rate of the conductive wire 25 in the above-described coated crimping portion is greater than or equal to the compression rate of the conductive wire 25 in the conductive wire crimping portion (that is, the compression amount of the conductive wire in the conductive wire crimping portion is covered and crimped. It is desirable that it is larger than the compression amount of the conducting wire in the portion. If the compression rate of the conductive wire 25 in the coated crimping portion is small, the cross-sectional area of the conductive wire 25 becomes smaller than that of the conductor crimped portion, and there is a risk of stress concentration and breakage when the coated conductive wire 23 is pulled. For this reason, the tensile strength of the covering conducting wire 23 with respect to the terminal 1 can be improved by making the compression rate of the conducting wire 25 in the covering crimping portion equal to or higher than the compressing rate of the conducting wire 25 in the conducting wire crimping portion. Note that the compressibility of the conductor 25 in the conductor crimping portion is preferably about 45 to 50%, for example.
　このような条件で圧着した後には、圧着部５と被覆部２７とが確実に密着して、圧着部５を封止することができる。特に、被覆部２７には適度な圧縮力が残り、永久ひずみも小さい。このため、圧着部５と被覆部２７との密着性が十分確保することができる。この際、圧着部５の後端部１９以外の他の部位は、接合部２１および封止部２２によって水密に封止されるため、圧着部５への水分の浸入を防止することができる。 After crimping under such conditions, the crimping part 5 and the covering part 27 can be securely adhered and the crimping part 5 can be sealed. In particular, an appropriate compressive force remains in the covering portion 27 and the permanent strain is small. For this reason, sufficient adhesion between the crimping part 5 and the covering part 27 can be ensured. At this time, other parts than the rear end part 19 of the crimping part 5 are sealed in a watertight manner by the joining part 21 and the sealing part 22, so that the intrusion of moisture into the crimping part 5 can be prevented.
　このように、被覆圧着部における導線２５の圧縮率を５０％～８０％とし、被覆部２７の圧縮率を４０％～９０％（さらに好ましくは５０％～８０％であり、５０％～７０％であればさらに望ましい）となるように圧縮を行うことで、導線２５および被覆部２７の両方について適切な圧縮量となり、互いの密着性も向上する。ここで、通常、導線２５よりも被覆部２７の圧縮量が大きくなりやすい。しかし、例えば導線２５が撚り線であれば、素線間の隙間によって導線全体が変形しやすい。このため、導線２５の圧縮量を大きくしやすい。 Thus, the compressibility of the conductor 25 in the coated crimping portion is 50% to 80%, and the compressibility of the covering portion 27 is 40% to 90% (more preferably 50% to 80%, 50% to 70%). If it is more desirable, the compression amount is appropriate for both the conductor 25 and the covering portion 27, and the mutual adhesion is also improved. Here, normally, the compression amount of the covering portion 27 is likely to be larger than that of the conductive wire 25. However, for example, if the conducting wire 25 is a stranded wire, the entire conducting wire is easily deformed by the gap between the strands. For this reason, it is easy to enlarge the compression amount of the conducting wire 25.
　また、被覆導線には、あらかじめ導線２５を圧縮して撚り合わせた圧縮導線が用いられる場合があるが、圧縮導線は、圧縮前にすでに圧縮されているため、それ以上の変形を加えにくい。このため、本発明では、導線２５が非圧縮導体であることが望ましい。 In some cases, a compressed conductor obtained by compressing and twisting the conductor 25 in advance is used as the coated conductor. However, since the compressed conductor is already compressed before compression, it is difficult to deform further. For this reason, in this invention, it is desirable for the conducting wire 25 to be an incompressible conductor.
　また、被覆部２７を構成する樹脂の縦弾性率が、常温（２０℃）において、１０ＭＰａ～５００ＭＰａの範囲のものについては、圧縮後の密着性を十分に確保することができる。 Further, when the longitudinal elastic modulus of the resin constituting the covering portion 27 is in the range of 10 MPa to 500 MPa at normal temperature (20 ° C.), sufficient adhesion after compression can be ensured.
　たとえば、上記縦弾性率が１０ＭＰａ未満では、樹脂が柔らかすぎて、密着力を確保することが困難である。また、上記縦弾性率が５００ＭＰａを超えると、樹脂が硬すぎて、同様に密着力を確保することが困難である。したがって、被覆部２７を構成する樹脂の縦弾性率は、常温（２０℃）において、１０ＭＰａ～５００ＭＰａであることが望ましく、さらに望ましくは、２８ＭＰａ～４２０ＭＰａである。このような樹脂としては、例えば、ポリ塩化ビニル（ＰＶＣ）、ポリエチレンであることが望ましい。尚、縦弾性率は、ＪＩＳ－Ｋ７１６１、７１６２などに従い求めることができる。 For example, if the longitudinal elastic modulus is less than 10 MPa, the resin is too soft and it is difficult to ensure adhesion. Moreover, when the said longitudinal elastic modulus exceeds 500 Mpa, resin is too hard and it is difficult to ensure contact | adhesion power similarly. Therefore, the longitudinal elastic modulus of the resin constituting the covering portion 27 is desirably 10 MPa to 500 MPa, more desirably 28 MPa to 420 MPa at normal temperature (20 ° C.). As such a resin, for example, polyvinyl chloride (PVC) or polyethylene is desirable. The longitudinal elastic modulus can be determined according to JIS-K7161, 7162 and the like.
　また、被覆部２７の厚さは、０．１６ｍｍ～０．４０ｍｍの範囲であることが望ましい。被覆部２７の厚みが薄すぎると、上記範囲の圧縮率とすると、圧縮時に破れる恐れがある。また、被覆部２７の厚みが厚すぎると、上記範囲の圧縮率とするための圧縮量が大きくなる。このため、被覆部２７の厚さは、０．１６ｍｍ～０．４０ｍｍの範囲であることが望ましい。 Also, the thickness of the covering portion 27 is desirably in the range of 0.16 mm to 0.40 mm. If the thickness of the covering portion 27 is too thin, there is a risk of tearing during compression if the compression ratio is in the above range. Moreover, when the thickness of the coating | coated part 27 is too thick, the compression amount for setting it as the compression rate of the said range will become large. For this reason, the thickness of the covering portion 27 is desirably in the range of 0.16 mm to 0.40 mm.
　本実施の形態によれば、被覆部２７の圧縮率が適正であるため、圧縮後の被覆部２７が塑性変形領域で変形させることができる。また、この際に、被覆部２７の永久ひずみが小さく、圧縮力を確保することができるため、圧着部５との間で密着性を確保することができる。このため、圧着部５と被覆部２７の止水性を確保することができる。 According to the present embodiment, since the compressibility of the covering portion 27 is appropriate, the compressed covering portion 27 can be deformed in the plastic deformation region. Further, at this time, since the permanent distortion of the covering portion 27 is small and a compressive force can be ensured, adhesion with the crimping portion 5 can be ensured. For this reason, it is possible to ensure the water stoppage of the crimping part 5 and the covering part 27.
　また、導線２５の圧縮率が適正であるため、圧縮後の導線２５の破断の恐れがなく、また、十分に変形させるため、導線２５の保持力にも優れる。 Moreover, since the compressibility of the conducting wire 25 is appropriate, there is no fear of the breaking of the conducting wire 25 after compression, and since the wire 25 is sufficiently deformed, the holding force of the conducting wire 25 is excellent.
（第２の実施の形態）
　次に、第２の実施の形態について説明する。図８は、第２の実施の形態にかかるワイヤハーネス３０ａを示す斜視図であり、図９は、ワイヤハーネス３０ａの圧着部５の縦断面図である。なお、以下の説明において、ワイヤハーネス３０と同一の機能を奏する構成については、図１等と同一の符号を付し、重複する説明を省略する。 (Second Embodiment)
Next, a second embodiment will be described. FIG. 8 is a perspective view showing a wire harness 30a according to the second embodiment, and FIG. 9 is a longitudinal sectional view of the crimping part 5 of the wire harness 30a. In the following description, components having the same functions as those of the wire harness 30 are denoted by the same reference numerals as those in FIG.
　ワイヤハーネス３０ａは、ワイヤハーネス３０とほぼ同様の構成であるが、圧着部５の内面に凸条部２９が形成される。凸条部２９は、被覆部２７の位置に形成される。また、凸条部２９は、圧着部５の内面の周方向に連続して環状に形成される。なお、凸条部２９の形成数は問わないが、２列以上離間して形成することが望ましい。 The wire harness 30 a has substantially the same configuration as that of the wire harness 30, but a ridge portion 29 is formed on the inner surface of the crimping portion 5. The protruding portion 29 is formed at the position of the covering portion 27. Further, the ridge portion 29 is formed in an annular shape continuously in the circumferential direction of the inner surface of the crimping portion 5. In addition, although the formation number of the protruding item | line parts 29 is not ask | required, it is desirable to form 2 or more rows apart.
　凸条部２９は、例えば、圧着時に形成される。例えば、金型の内面に突起を形成しておくことで、圧着部５の一部が、突起によって押し込まれる。したがって、凸条部２９の外面には凹溝７が形成される。このように、凸条部２９によって、他の部位よりも強く被覆部２７を圧縮することで、より確実に被覆部２７と圧着部５との密着性を確保することができる。 The protruding line portion 29 is formed, for example, at the time of pressure bonding. For example, by forming a protrusion on the inner surface of the mold, a part of the crimping portion 5 is pushed by the protrusion. Therefore, the concave groove 7 is formed on the outer surface of the ridge 29. In this way, by compressing the covering portion 27 more strongly than the other portions by the ridge portion 29, the adhesion between the covering portion 27 and the crimping portion 5 can be ensured more reliably.
　このように、凸条部２９を形成する場合には、凸条部２９における断面において、前述した圧縮率の範囲となるようにする。このようにすることで、確実に被覆部２７による止水性と、導線２５の保持を行いことができる。 Thus, when the ridge portion 29 is formed, the cross section of the ridge portion 29 is set within the compression rate range described above. By doing in this way, the water stop by the coating | coated part 27 and the holding | maintenance of the conducting wire 25 can be performed reliably.
　第２の実施の形態によれば、第１の実施の形態と同様の効果を得ることができる。また、凸条部２９によって、より高い止水性を確保することができる。 According to the second embodiment, an effect similar to that of the first embodiment can be obtained. Further, the protruding strip portion 29 can ensure higher water stoppage.
　次に、本発明に従うワイヤハーネス及び比較としてのワイヤハーネスを試作し、各試料ついて性能試験を行ったので以下に説明する。 Next, a wire harness according to the present invention and a comparative wire harness were prototyped and a performance test was performed on each sample, which will be described below.
　図６に示される特性を有する被覆を有する被覆導線を用い、各条件で圧着部５を圧着したワイヤハーネス３０を１２０℃で１２０時間だけ高温放置を行った後、塩水噴霧試験ＪＩＳ　Ｃ６００６８-２-１１で規定される塩水噴霧を４８ｈｒ行った。 After the wire harness 30 with the crimped portion 5 crimped under each condition was left at a high temperature for 120 hours at 120 ° C. using a coated conductor having a coating having the characteristics shown in FIG. 6, the salt spray test JIS C60068-2- 11 was sprayed with salt water for 48 hours.
　試験前後の抵抗変化を示したところ、圧縮率が９５％では、１ｍΩ以上の抵抗変化が確認された。また、圧縮率が４０％～９０％の範囲では、抵抗変化は０．５ｍΩ以下であり、抵抗変化はほとんど見られなかった。なお、圧縮率が３５％では、電線に損傷が確認された。 When the resistance change before and after the test was shown, a resistance change of 1 mΩ or more was confirmed at a compression ratio of 95%. Further, when the compression ratio was in the range of 40% to 90%, the resistance change was 0.5 mΩ or less, and almost no resistance change was observed. In addition, when the compression rate was 35%, damage to the electric wire was confirmed.
　次に、同様にして、図６に示される特性を有する被覆を有する被覆導線を用い、各条件で圧着部５を圧着したワイヤハーネス３０を１２０℃で１２０時間だけ高温放置を行った後、被覆導線から端子に向かって空気を送り、後端部から空気が漏れるか否かについて実験した。図１０には、実験方法の概要を示す。実験は、水を入れた水槽４１中に被覆導線２３に圧着された端子１を入れ、ワイヤハーネス３０の端部から端子１に向かって必要に応じてレギュレータ４２によって加圧空気を送った。 Next, in the same manner, the coated wire having the characteristics shown in FIG. 6 was used, and the wire harness 30 with the crimped portion 5 crimped under each condition was left at a high temperature for 120 hours at 120 ° C. An experiment was conducted to check whether air was leaked from the rear end portion by sending air from the conductor toward the terminal. FIG. 10 shows an outline of the experimental method. In the experiment, the terminal 1 crimped to the covered conductor 23 was placed in a water tank 41 containing water, and pressurized air was sent from the end of the wire harness 30 toward the terminal 1 by the regulator 42 as necessary.
　なお、試験は、３ｋＰａ、３０ｋＰａ、５０ｋＰａの３水準で行った。この際、３ｋＰａについては、レギュレータ４２を用いずに、端子を水面から３０ｃｍ水没させて３ｋＰａの状況とした。結果を表１に示す。 The test was conducted at three levels of 3 kPa, 30 kPa, and 50 kPa. At this time, with respect to 3 kPa, the terminal was submerged 30 cm from the water surface without using the regulator 42 to obtain a state of 3 kPa. The results are shown in Table 1.
Figure JPOXMLDOC01-appb-T000001
Figure JPOXMLDOC01-appb-T000001
　各条件において、ｎ＝１０の試験を行い、リークが一つでも確認されたものを「ＢＡＤ」とし、リークの確認されなかったものを「ＧＯＯＤ」とした。 In each condition, a test of n = 10 was performed, and “BAD” was defined as “BAD” when no leak was confirmed, and “GOOD” was defined as no leak was confirmed.
　表１より、被覆圧着部における被覆部の圧縮率が４０～９０％であり、かつ、被覆圧着部における導線の圧縮率が５０～８０％の条件を満たす、Ｎｏ．５、７～１６、１８は、３ｋＰａでのリークが確認されなかった。また、被覆圧着部における被覆部の圧縮率が５０～８０％であり、かつ、被覆圧着部における導線の圧縮率が５０～８０％の条件を満たす、Ｎｏ．７～１６は、３０ｋＰａでもリークが確認されなかった。さらに、被覆圧着部における被覆部の圧縮率が５０～７０％であり、かつ、被覆圧着部における導線の圧縮率が５０～８０％の条件を満たす、Ｎｏ．７～１３は、５０ｋＰａでもリークが確認されなかった。 From Table 1, No. 1 satisfies the condition that the compressibility of the coated portion in the coated crimp portion is 40 to 90% and the compressibility of the conductive wire in the coated crimp portion is 50 to 80%. No leakage at 3 kPa was confirmed for 5, 7 to 16 and 18. Further, in the case where the compression ratio of the covering portion in the covering and crimping portion is 50 to 80% and the compression ratio of the conductive wire in the covering and crimping portion is 50 to 80%, In Nos. 7 to 16, no leak was confirmed even at 30 kPa. Furthermore, the compression rate of the coated part in the coated crimping part is 50 to 70%, and the compression rate of the conductive wire in the coated crimped part satisfies the conditions of 50 to 80%. In Nos. 7 to 13, no leak was confirmed even at 50 kPa.
　以上、添付図を参照しながら、本発明の実施の形態を説明したが、本発明の技術的範囲は、前述した実施の形態に左右されない。当業者であれば、特許請求の範囲に記載された技術的思想の範疇内において各種の変更例または修正例に想到し得ることは明らかであり、それらについても当然に本発明の技術的範囲に属するものと了解される。 The embodiment of the present invention has been described above with reference to the accompanying drawings, but the technical scope of the present invention is not affected by the above-described embodiment. It is obvious for those skilled in the art that various modifications or modifications can be conceived within the scope of the technical idea described in the claims, and these are naturally within the technical scope of the present invention. It is understood that it belongs.
　例えば、実施例は、電線にアルミニウム（不可避元素を含む）を使った場合を記載したが、これに限定されず、電線に銅を使っても良い。また、本発明では、前述した各実施形態は、互いに組み合わせることができることは言うまでもない。 For example, in the embodiment, the case where aluminum (including inevitable elements) is used for the electric wire is described, but the present invention is not limited to this, and copper may be used for the electric wire. In the present invention, it goes without saying that the above-described embodiments can be combined with each other.
　また、本発明にかかるワイヤハーネスを複数本束ねて使用することもできる。本発明では、このように複数本のワイヤハーネスが束ねられた構造体を、ワイヤハーネス構造体と称する。 Also, a plurality of wire harnesses according to the present invention can be bundled and used. In the present invention, a structure in which a plurality of wire harnesses are bundled in this way is referred to as a wire harness structure.
　１………端子
　３………端子本体
　５………圧着部
　７………凹溝
　１５………弾性接触片
　１７………前端部
　１９………後端部
　２１………接合部
　２２………封止部
　２３………被覆導線
　２５………導線
　２７………被覆部
　２９………凸条部
　３０、３０ａ………ワイヤハーネス
　３１ａ、３１ｂ………金型
　４１………水槽
　４３………レギュレータ DESCRIPTION OF SYMBOLS 1 ......... Terminal 3 ......... Terminal main body 5 ......... Pressure bonding part 7 ......... Dove groove 15 ......... Elastic contact piece 17 ......... Front end 19 ......... Rear end 21 ......... Junction 22 ......... Sealed portion 23 ......... Coated conductor 25 ......... Conducted wire 27 ......... Coated portion 29 ......... Projected ridges 30, 30a ......... Wire harnesses 31a, 31b ......... Mold 41 ......... Water tank 43 ......... Regulator

Claims (10)

  1. 　被覆導線と端子とが接続されるワイヤハーネスであって、
    　前記端子は、前記被覆導線が圧着される圧着部と、端子本体と、を具備し、
    　前記圧着部は、被覆部を圧着する被覆圧着部と、前記被覆部から露出する導線を圧着する導線圧着部とを有し、前記被覆導線が挿入される部位を除き、他の部位が封止されており、
    　前記被覆圧着部における、前記導線の圧縮率が５０％～８０％であり、前記被覆部の圧縮率が４０％～９０％であることを特徴とするワイヤハーネス。     A wire harness in which a coated conductor and a terminal are connected,
    The terminal comprises a crimping part to which the coated conductor is crimped, and a terminal body,
    The crimping part has a coated crimping part that crimps the covering part and a conductive wire crimping part that crimps the conductive wire exposed from the covering part, and other parts are sealed except the part where the coated conductive wire is inserted. Has been
    The wire harness characterized in that a compression rate of the conductive wire in the coated crimping portion is 50% to 80%, and a compression rate of the coated portion is 40% to 90%.
  2. 　前記被覆部の圧縮率が５０～８０％であることを特徴とする請求項１記載のワイヤハーネス。 The wire harness according to claim 1, wherein a compression ratio of the covering portion is 50 to 80%.
  3. 　前記被覆圧着部における前記導線の圧縮率は、前記導線圧着部における前記導線の圧縮率に比べて大きいか等しいことを特徴とする請求項１記載のワイヤハーネス。 The wire harness according to claim 1, wherein a compression rate of the conducting wire in the coated crimping portion is greater than or equal to a compression rate of the conducting wire in the conducting wire crimping portion.
  4. 　前記被覆部を構成する樹脂の縦弾性率が、２０℃において、１０ＭＰａ～５００ＭＰａの範囲であることを特徴とする請求項１記載のワイヤハーネス。 The wire harness according to claim 1, wherein the longitudinal elastic modulus of the resin constituting the covering portion is in the range of 10 MPa to 500 MPa at 20 ° C.
  5. 　前記被覆部の厚さが、０．１６ｍｍ～０．４０ｍｍの範囲であることを特徴とする請求項１記載のワイヤハーネス。 The wire harness according to claim 1, wherein a thickness of the covering portion is in a range of 0.16 mm to 0.40 mm.
  6. 　前記導線は、純アルミニウムであることを特徴とする請求項１記載のワイヤハーネス。 The wire harness according to claim 1, wherein the conducting wire is pure aluminum.
  7. 　前記導線は、撚り線であることを特徴とする請求項１記載のワイヤハーネス。 The wire harness according to claim 1, wherein the conducting wire is a stranded wire.
  8. 　圧着前の前記導線は、非圧縮導体であることを特徴とする請求項１記載のワイヤハーネス。 2. The wire harness according to claim 1, wherein the lead wire before crimping is an uncompressed conductor.
  9. 　被覆導線と端子との接続方法であって、
    　前記端子は、前記被覆導線が圧着される圧着部と、端子本体と、を具備し、
    　前記圧着部は、被覆部を圧着する被覆圧着部と、前記被覆部から露出する導線を圧着する導線圧着部とを有し、前記被覆導線が挿入される部位を除き、他の部位が封止されており、
    　前記圧着部に前記被覆導線を挿入し、前記圧着部を圧着する際に、前記被覆圧着部における、前記導線の圧縮率を５０％～８０％とし、前記被覆部の圧縮率を４０％～９０％とすることを特徴とする被覆導線と端子との接続方法。     A method of connecting a coated conductor and a terminal,
    The terminal comprises a crimping part to which the coated conductor is crimped, and a terminal body,
    The crimping part has a coated crimping part that crimps the covering part and a conductive wire crimping part that crimps the conductive wire exposed from the covering part, and other parts are sealed except the part where the coated conductive wire is inserted. Has been
    When the coated conductor is inserted into the crimping part and the crimping part is crimped, the compression rate of the conductor in the coated crimping part is 50% to 80%, and the compression rate of the coating part is 40% to 90%. %. A method for connecting a coated conductive wire and a terminal.
  10. 　複数本のワイヤハーネスが束ねられたワイヤハーネス構造体であって、
    　前記ワイヤハーネスは、被覆導線と端子とが接続されており、
    　前記端子は、前記被覆導線が圧着される圧着部と、端子本体と、を具備し、
    　前記圧着部は、被覆部を圧着する被覆圧着部と、前記被覆部から露出する導線を圧着する導線圧着部とを有し、前記被覆導線が挿入される部位を除き、他の部位が封止されており、
    　前記被覆圧着部における、前記導線の圧縮率が５０％～８０％であり、前記被覆部の圧縮率が４０％～９０％であることを特徴とするワイヤハーネス構造体。     A wire harness structure in which a plurality of wire harnesses are bundled,
    The wire harness is connected to a coated conductor and a terminal,
    The terminal comprises a crimping part to which the coated conductor is crimped, and a terminal body,
    The crimping part has a coated crimping part that crimps the covering part and a conductive wire crimping part that crimps the conductive wire exposed from the covering part, and other parts are sealed except the part where the coated conductive wire is inserted. Has been
    A wire harness structure characterized in that a compression rate of the conducting wire in the coated crimping portion is 50% to 80%, and a compression rate of the coated portion is 40% to 90%.
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EP3125369A1 (en) 2017-02-01
KR101833659B1 (en) 2018-02-28
JPWO2015146819A1 (en) 2017-04-13
KR20160110451A (en) 2016-09-21
US10305240B2 (en) 2019-05-28
CN105940557B (en) 2019-08-16
US20180175574A1 (en) 2018-06-21
EP3125369A4 (en) 2017-10-25
EP3125369B1 (en) 2021-04-21
JP6117426B2 (en) 2017-04-19
CN105940557A (en) 2016-09-14

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